2000 Honda InsightFACTORY OEM SERVICE PROCEDURE

DTC P1445 (62): Bypass Contactor Problem

  1. Reset the MCM (see HOW TO RESET THE MCM ).
  2. Turn the ignition switch ON (II), and turn off all accessories that create load: headlights, blower fan, rear defogger, and air conditioner.

    Is DTC P1445 (62) indicated? 

    1. YES  - Go to step 3.
    2. NO  - Intermittent failure, system is OK at this time. Check for poor connections or loose terminals at the DC-DC converter, the bypass contactor, and the MCM.
  3. Turn the ignition switch OFF.
  4. Turn the battery module switch OFF (see TURNING OFF POWER TO THE HIGH VOLTAGE CIRCUIT ).
  5. Remove the IPU lid, and make sure there is 30 V or less at the junction terminals.
  6. Disconnect the DC-DC converter 8P connector.
  7. Turn the battery module switch ON.
  8. Turn the ignition switch ON (II).

    Is DTC P1445 (62) indicated? 

    1. YES  - Go to step  13.
    2. NO  - Go to step 9.
  9. Turn the ignition switch OFF.
  10. Turn the battery module switch OFF (see TURNING OFF POWER TO THE HIGH VOLTAGE CIRCUIT ).
  11. Connect DC-DC converter 8P connector terminal No. 6 to body ground with a jumper wire.
    Fig 1: Connecting DC-DC Converter 8P Connector Terminal No. 6 To Body Ground Using Jumper Wire
    G03681324Courtesy of AMERICAN HONDA MOTOR CO., INC.
  12. Check for continuity between body ground and MCM connector terminal A27.
    Fig 2: Checking Continuity Between Body Ground And MCM Connector Terminal A27
    G03681325Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Is there continuity? 

    1. YES  - Repair open in the high voltage line. If the line is OK, replace these items:
    2. NO  - Repair open in the wire between the DC-DC converter and the MCM (A27).
  13. Turn the ignition switch OFF.
  14. Turn the battery module switch OFF (see TURNING OFF POWER TO THE HIGH VOLTAGE CIRCUIT ).
  15. Disconnect the junction board 16P connector.
  16. Connect a voltmeter between junction board 16P connector terminals No. 7 and No. 10, then turn the ignition switch ON (II).
    Fig 3: Connecting Voltmeter Between Junction Board 16P Connector Terminals No. 7 And 10
    G03681326Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Is there battery voltage momentarily? 

    1. YES  -
      • Replace the battery module (see BATTERY MODULE REMOVAL/INSTALLATION ).
      • Substitute a known-good MCM and BCM module, and recheck. If the symptom/indication goes away, replace the original MCM and BCM module.
    2. NO  - Go to step 17.
  17. Turn the ignition switch OFF.
  18. Measure voltage between MCM connector terminals A8 and A10, then turn the ignition switch ON (II).
    Fig 4: Measuring Voltage Between MCM Connector Terminals A8 And A10
    G03681327Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Is there battery voltage momentarily? 

    1. YES  - Repair open in the wire between the junction board 16P connector and the MCM (A8).
    2. NO  -
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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